Methods of making and using inductive devices with splits

Abstract

Methods and apparatus for providing enhanced coupled inductive devices. In one embodiment, an inductive device is disclosed that is suitable in Ethernet applications with data speeds exceeding one (1) Gbps. Specifically, the inductive devices described herein possess a high level of magnetic and capacitive coupling between the wires of the windings. Moreover, the inductive devices described herein are suitable for automated processes, thereby reducing the overall costs associated with their manufacture and use. Furthermore, methods for manufacturing and using these aforementioned inductive devices are also disclosed. For example, the aforementioned inductive devices may readily be incorporated into ICMs thereby replacing, in their entirety or in part, manually wound toroidal transformers.

What is claimed is: 
     
       1. A method of manufacturing an inductive device, comprising:
 obtaining a core comprising an axial portion, a first flange portion and a second flange portion, with the first flange portion being disposed on an opposing side of the axial portion with the second flange portion, the first flange portion comprising a first plurality of interface connections and the second flange portion comprising a second plurality of interface connections; 
 securing a first of a pair of primary windings to the first flange portion; 
 securing a first of a pair of secondary windings to the first flange portion; 
 winding the first of the pair of primary and secondary windings about the axial portion of the core in a first direction; 
 securing the first of the pair of primary windings to the second flange portion; 
 securing the first of the pair of secondary windings to the second flange portion; 
 securing a second of the pair of primary windings to the second flange portion; 
 securing a second of the pair of secondary windings to the second flange portion; and 
 subsequent to the winding of the first of the pair of primary and secondary windings in the first direction, winding the second of the pair of primary and secondary windings about the axial portion of the core in a second direction opposite to the first direction, so as to complete a complete set of windings within two traversals across the axial portion of the core, the said complete set of windings is composed of the first of the pair of primary and secondary windings and the second of the pair of primary and secondary windings. 
 
     
     
       2. The method of  claim 1 , further comprising attaching an end cap core portion to the first flange portion and the second flange portion. 
     
     
       3. The method of  claim 1 , wherein:
 the securing of the first of the pair of primary windings to the second flange portion comprises forming a first center tap connection at the second flange portion; and 
 the securing of the first of the pair of secondary windings to the second flange portion comprises forming a second center tap connection at the second flange portion. 
 
     
     
       4. The method of  claim 1 , further comprising:
 subsequent to the winding of the second of the pair of primary windings, securing the second of the pair of primary windings to the first flange portion; and 
 subsequent to the winding of the second of the pair of secondary windings, securing the second of the pair of secondary windings to the first flange portion. 
 
     
     
       5. The method of  claim 1 , wherein obtaining of the core comprises disposing four interface connections on each of the first flange portion and the second flange portion, such that the number of the first plurality of interface connections of the first flange portion is four and the number of the second plurality of interface connections of the second flange portion is four. 
     
     
       6. A method of manufacturing an inductive device, the method comprising:
 securing a first primary winding to (i) a first flange associated with an inductive core component and (ii) a second flange associated with the inductive core component; 
 securing a second primary winding to (i) the first flange and (ii) the second flange; 
 securing a first secondary winding to (i) the first flange and (ii) the second flange; and 
 securing a second secondary winding to (i) the first flange and (ii) the second flange; 
 wherein securing of the first and second primary windings and the first and second secondary windings comprise winding each of the first and second primary windings and the first and second secondary windings about at least a portion of the inductive core component; 
 wherein subsequent to the winding of the first primary winding and the first secondary winding about at least the portion of the inductive core component in a first direction, winding the second primary winding and the second secondary winding about at least the portion of the inductive core component in a second direction opposite to the first direction, so as to complete a complete set of windings within two traversals across the inductive core component, the said complete set of windings is composed of the first and second primary windings and the first and second secondary windings. 
 
     
     
       7. The method of  claim 6 , further comprising:
 mounting the inductive device to a substrate for use in a data-communication application. 
 
     
     
       8. The method of  claim 6 , wherein securing of the first primary winding comprises securing the first primary winding to a first termination pad of the first flange and a first termination pad of the second flange;
 wherein securing of the second primary winding comprises securing the second primary winding to a second termination pad of the first flange and a second termination pad of the second flange; 
 wherein securing of the first secondary winding comprises securing the first secondary winding to a third termination pad of the first flange and a third termination pad of the second flange; 
 wherein securing of the second secondary winding comprises securing the second secondary winding to a fourth termination pad of the first flange and a fourth termination pad of the second flange; 
 wherein each of the first flange and the second flange has four termination pads disposed thereon, and the said four termination pads are the first termination pad, the second termination pad, the third termination pad, and the fourth termination pad.